U.S. patent number 10,361,048 [Application Number 15/151,680] was granted by the patent office on 2019-07-23 for pyrotechnic circuit protection systems, modules, and methods.
This patent grant is currently assigned to EATON INTELLIGENT POWER LIMITED. The grantee listed for this patent is EATON INTELLIGENT POWER LIMITED. Invention is credited to Michael Craig Henricks, Joseph James Ventura, Patrick Alexander von zur Muehlen.
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United States Patent |
10,361,048 |
von zur Muehlen , et
al. |
July 23, 2019 |
Pyrotechnic circuit protection systems, modules, and methods
Abstract
A pyrotechnic circuit protection system includes a first
connection terminal, a second connection terminal and a plurality
of pyrotechnic modules connected between the first and second
connection terminals. Each of the pyrotechnic modules includes a
nonconductive housing and electrical connectors facilitating
plug-in connection of the pyrotechnic modules to one another. A
single control module may control and coordinate a plurality of
pyrotechnic disconnect modules.
Inventors: |
von zur Muehlen; Patrick
Alexander (Wildwood, MO), Henricks; Michael Craig
(Ballwin, MO), Ventura; Joseph James (Eureka, MO) |
Applicant: |
Name |
City |
State |
Country |
Type |
EATON INTELLIGENT POWER LIMITED |
Dublin OT |
N/A |
IE |
|
|
Assignee: |
EATON INTELLIGENT POWER LIMITED
(Dublin, IE)
|
Family
ID: |
58701863 |
Appl.
No.: |
15/151,680 |
Filed: |
May 11, 2016 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20170330714 A1 |
Nov 16, 2017 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01H
39/00 (20130101); H01H 39/006 (20130101); H01H
9/02 (20130101); H01R 24/76 (20130101); H01H
9/106 (20130101) |
Current International
Class: |
H01H
39/00 (20060101); H01H 9/02 (20060101); H01R
24/76 (20110101); H01H 9/10 (20060101) |
Field of
Search: |
;337/30,401,414
;200/50.02 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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|
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|
|
10049071 |
|
Apr 2002 |
|
DE |
|
102009023801 |
|
Feb 2010 |
|
DE |
|
20201004061 |
|
Jun 2010 |
|
DE |
|
202010004061 |
|
Jul 2010 |
|
DE |
|
102011014343 |
|
Sep 2012 |
|
DE |
|
102012022083 |
|
May 2014 |
|
DE |
|
2293345 |
|
Mar 2011 |
|
EP |
|
3014594 |
|
Jun 2015 |
|
FR |
|
2489101 |
|
Sep 2012 |
|
GB |
|
Other References
Virgin Jean-Marc, Kablaoui Hassan, "Safety device for disconnecting
high voltage battery in e.g. electric vehicle from electric circuit
during short circuit, has safety fuse connected parallel to
pyrotechnical fuses, and series resistor connected upstream to
safety fuse", Feb. 4, 2010, Daimler AG, Entire Document
(Translation of DE102009023801). cited by examiner .
Bornhorst Dieter et.al., "Circuit protection device, especially in
vehicles, has terminals protruding out of housing formed in one
piece with conducting section inside housing forming preferred
breakage point", Apr. 25, 2002, MICRONAS GMBH, Entire Document
(Translation of DE10049071). cited by examiner .
"Elektrisch koppelbares Installationsgerat", Jun. 24, 2010, THEBEN
AG, Entire Document (Translation of DE202010004061). cited by
examiner .
Tautz Juergen, "Pyrotechnically actuated fuse for a motor vehicle",
Sep. 20, 2012, GM Global Tech Operations INC, Entire Document
(Translation of DE102011014343). cited by examiner .
International Search Report and Written Opinion for International
Application No. PCT/US2817029547, dated Jul. 24, 2017, 16 pages.
cited by applicant .
Extended European Search Report for Application No. 17170514.8,
dated Jul. 24, 2017, 9 pages. cited by applicant.
|
Primary Examiner: Vortman; Anatoly
Assistant Examiner: Sul; Stephen S
Attorney, Agent or Firm: Armstrong Teasdale LLP
Claims
What is claimed is:
1. A modular pyrotechnic circuit protection system comprising: a
first pyrotechnic disconnect module comprising: a nonconductive
housing including first and second side surfaces opposing one
another; a first electrical connector on the first side surface,
the first electrical connector positioned on the first side surface
to mechanically and electrically join a mating electrical connector
of a second pyrotechnic disconnect module adjacent to the first
pyrotechnic disconnect module on the first side surface; a second
electrical connector on the second side surface, the second
electrical connector positioned on the second side surface to
mechanically and electrically join a mating electrical connector of
a third pyrotechnic disconnect module adjacent to the first
pyrotechnic disconnect module on the second side surface; a
pyrotechnic disconnect element inside the nonconductive housing and
electrically connected to at least one of the first or second
electrical connectors; and first and second terminals coupled to
the nonconductive housing for connection to external circuitry;
wherein at least one of the second or third pyrotechnic disconnect
modules is a pyrotechnic control module communicating a trigger
command to the pyrotechnic disconnect element via the first or
second electrical connector in response to a detected electrical
fault condition.
2. The system of claim 1, wherein the first electrical connector is
a male connector and wherein the second electrical connector is a
female connector.
3. The system of claim 1, wherein a pass through electrical
connection is established in the nonconductive housing from the
first electrical connector, through the first pyrotechnic
disconnect element, and to the second electrical connector to
establish a pass through electrical connection to the mating
electrical connector of the third pyrotechnic disconnect
module.
4. The system of claim 1, wherein the pyrotechnic disconnect
element releases one of chemical energy, electrical energy or
mechanical energy to disconnect the first and second terminals from
one another.
5. The system of claim 1, wherein the nonconductive housing is
asymmetrical.
6. The system of claim 1, in combination with the pyrotechnic
control module.
7. The system of claim 1, wherein the first and second electrical
connectors are in-line with one another on the first and second
side surfaces.
8. The system of claim 1, wherein the first electrical connector
includes first and second prongs and wherein the second electrical
connector includes first and second apertures.
9. The system of claim 8, wherein the first prong establishes a
control connection to the pyrotechnic disconnect element, and
wherein the second prong establishes a pass through electrical
connection to the second pyrotechnic disconnect module.
10. A modular pyrotechnic circuit protection system comprising: a
modular pyrotechnic control module comprising: a nonconductive
housing comprising first and second side surfaces opposing one
another; an electrical connector exposed on the first or second
side surface; a pyrotechnic control circuit inside the
nonconductive housing and electrically connected to the electrical
connector; wherein the electrical connector is located to
mechanically and electrically join an aligned electrical connector
provided on a mating pyrotechnic disconnect module including a
pyrotechnic disconnect element; wherein the mating pyrotechnic
disconnect module is separately provided from but adjacent to the
modular pyrotechnic control module and wherein the aligned
electrical connector establishes a plug-in control connection to
the electrical connector of the modular pyrotechnic control module;
wherein the pyrotechnic control circuit communicates, via the
plug-in control connection, a trigger command that activates the
pyrotechnic disconnect element in the mating pyrotechnic disconnect
module; and first and second terminals coupled to the nonconductive
housing for connection to external circuitry.
11. The system of claim 10, wherein the electrical connector is a
male connector or a female connector.
12. The system of claim 10, further comprising a cable coupled to
the modular pyrotechnic control module and establishing
communication with a remote device.
13. The system of claim 10, wherein in response to a detected
electrical fault condition, the pyrotechnic control circuit outputs
the trigger command signal.
14. The system of claim 10, wherein the nonconductive housing is
symmetrical.
15. The system of claim 10, in combination with the mating
pyrotechnic disconnect module.
16. A pyrotechnic circuit protection system comprising: a first
connection terminal; a second connection terminal; a plurality of
side-by-side pyrotechnic modules connected in parallel to one
another between the first and second connection terminals, each of
the plurality of side-by-side pyrotechnic modules including a
nonconductive housing and respective electrical connectors
facilitating plug-in mechanical and electrical interconnection of
the side-by-side pyrotechnic modules to one another; and an arc
mitigation fuse separately provided from the plurality of
side-by-side pyrotechnic modules and connected between the first
and second connection terminals in parallel to the plurality of
side-by-side pyrotechnic modules.
17. The pyrotechnic circuit protection system of claim 16, wherein
the plurality of side-by-side pyrotechnic modules includes at least
one pyrotechnic disconnect module including a pyrotechnic
disconnect element and a pyrotechnic control module generating a
trigger command that activates the pyrotechnic disconnect element
in the mating pyrotechnic disconnect module in response to a
detected electrical fault condition, wherein the at least one
pyrotechnic disconnect element and the pyrotechnic control module
are mechanically and electrically engaged to one another via the
respective electrical connectors.
18. The pyrotechnic circuit protection system of claim 16, wherein
the plurality of side-by-side pyrotechnic modules includes a
plurality of pyrotechnic disconnect modules each having a
pyrotechnic disconnect element therein, the plurality of
side-by-side pyrotechnic modules mechanically and electrically
engaged to one another via the respective electrical
connectors.
19. The pyrotechnic circuit protection system of claim 16, further
comprising a limiter element connected in series with at least some
of the plurality of side-by-side pyrotechnic modules.
20. The pyrotechnic circuit protection system of claim 16, wherein
at least one of the first connection terminal and the second
connection terminal is a bus bar.
21. The pyrotechnic circuit protection system of claim 16, wherein
the plurality of side-by-side pyrotechnic modules includes a
plurality of pyrotechnic disconnect modules and a pyrotechnic
control module mechanically and electrically engaged to one another
via the respective electrical connectors, wherein the pyrotechnic
control module is operative to activate the plurality of
pyrotechnic disconnect modules individually or simultaneously.
Description
BACKGROUND OF THE INVENTION
The field of the invention relates generally to electrical circuit
protection devices and related systems and methods, and more
specifically to pyrotechnic circuit protection devices and related
systems and methods.
Pyrotechnic circuit protection devices are known that include
terminals for connection to a circuit and a pyrotechnic disconnect
feature that releases energy to disconnect the terminals inside the
device. The pyrotechnic disconnect feature may include stored
chemical, electrical or mechanical energy that is released via
actuation of a pyrotechnic charge to sever an electrical connection
between the terminals of the device. As such, pyrotechnic circuit
protection devices are sometimes referred to as pyrotechnic
disconnects or pyrotechnic switches. Once activated, such devices
can electrically isolate load-side circuitry from line-side
circuitry through the pyrotechnic circuit protection device when
predetermined fault conditions occur in the line-side circuitry and
prevent possible damage to load-side circuitry that the fault
condition may otherwise present.
Pyrotechnic circuit protection devices are advantageous for their
quick and reliable operation regardless of the energy (voltage and
current) in the circuit completed through the device when fault
conditions are identified. This is because the energy needed to
open the device comes from a chemically stored source in the
pyrotechnic unit rather than the energy of the circuit fault (as in
fusible circuit protector) or from stored mechanical energy (as in
conventional circuit breaker devices).
Known pyrotechnic circuit protection devices remain disadvantaged
in some aspects, however, that to date have limited their use to a
relatively small set of niche applications. Improvements are
desired.
BRIEF DESCRIPTION OF THE DRAWINGS
Non-limiting and non-exhaustive embodiments are described with
reference to the following Figures, wherein like reference numerals
refer to like parts throughout the various views unless otherwise
specified.
FIG. 1 is a first perspective view of an exemplary embodiment of a
pyrotechnic circuit protection module according to the present
invention.
FIG. 2 is a second perspective view of the pyrotechnic circuit
protection module shown in FIG. 1.
FIG. 3 is a perspective view of an exemplary embodiment of a
pyrotechnic control module for use with the pyrotechnic circuit
protection device module in FIGS. 1 and 2 according to the present
invention.
FIG. 4 is a perspective view of a first exemplary embodiment of a
pyrotechnic circuit protection system according to the present
invention including the pyrotechnic circuit protection module of
FIGS. 1 and 2 and the pyrotechnic control module shown in FIG.
3.
FIG. 5 is a block diagram of the exemplary system shown in FIG.
4.
FIG. 6 is a perspective view of a second exemplary embodiment of a
pyrotechnic circuit protection system according to the present
invention including the pyrotechnic circuit protection modules of
FIGS. 1 and 2 and the pyrotechnic control module shown in FIG.
3.
FIG. 7 is a perspective view of a third exemplary embodiment of a
pyrotechnic circuit protection system according to the present
invention including pyrotechnic circuit protection modules.
FIG. 8 is a perspective view of a fourth exemplary embodiment of a
pyrotechnic circuit protection system according to the present
invention including pyrotechnic circuit protection modules shown in
FIGS. 1 and 2 with another exemplary embodiment of a pyrotechnic
control module.
FIG. 9 is a perspective view of the pyrotechnic control module
shown in FIG. 8.
FIG. 10 is a perspective view of a fifth exemplary embodiment of a
pyrotechnic circuit protection system according to the present
invention including the pyrotechnic circuit protection modules
shown in FIGS. 1 and 2 with the pyrotechnic control module shown in
FIG. 3.
FIG. 11 is a perspective view of a sixth exemplary embodiment of a
pyrotechnic circuit protection system according to the present
invention including the pyrotechnic circuit protection modules
shown in FIGS. 1 and 2 with the pyrotechnic control module shown in
FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
In order to understand the present invention to its fullest extent,
a discussion of the state of the art of pyrotechnic circuit
protection devices and its limitations is described below, followed
by a discussion of exemplary embodiments of the present invention
that address and overcome those limitations and beneficially
satisfy longstanding and unfulfilled needs in the art.
Conventional pyrotechnic circuit protection devices tend to be
disadvantaged in certain aspects that have until now been an
impediment to their widespread use and adoption. Instead,
conventional pyrotechnic circuit protection device tend to be
employed only in certain niche applications.
For example, known pyrotechnic circuit protection devices tend to
be limited to relatively low voltage applications (typically 70V or
less) and relatively low current applications (typically 100 A or
less). For voltage and current applications outside this range,
conventional pyrotechnic circuit protection devices are generally
not considered.
Pyrotechnic circuit protection devices require an external
actuation source and a monitoring system to detect fault conditions
and activate the pyrotechnic disconnect feature. Providing
actuation sources and monitoring systems and connecting them to the
pyrotechnic circuit protection devices can be impractical and
inconvenient relative to other types of circuit protection devices.
Such issues are multiplied over the number of pyrotechnic circuit
protection devices needed to protect desired circuitry.
Conventional pyrotechnic circuit protection devices generally do
not include arc mitigation elements, so for higher voltage systems
another circuit protection device (typically a fuse) is often used
in parallel to a pyrotechnic circuit protection device. This
increases the cost and expense of implementing pyrotechnic circuit
protection devices, and is multiplied over the number of
pyrotechnic circuit protection devices needed to protect desired
circuitry.
Finally, pyrotechnic circuit protection devices tend to be
expensive to develop for specific applications, and are not
compatible with existing circuit protection accessories such as
fuse holders, fuse blocks, etc. that accommodate fuses and
facilitate ease of connection to electrical circuits. Without a
great deal of effort and analysis to determine the correspondence
between pyrotechnic circuit protection devices and other circuit
protection devices they are not easy to use as a drop-in
replacement to other types of circuit protectors such as fuses.
Exemplary embodiments of the present invention are described below
that beneficially overcome these and other disadvantages in the
art. As explained in detail below, modular pyrotechnic circuit
protection devices are proposed for use in combination with modular
pyrotechnic control modules that provide an easily configurable
system that may be readily used with standard fuses, terminals,
controllers and other components to meet a wide variety of circuit
protection specifications and needs at relatively low cost and with
general compatibility with established circuit protection fuse
classes and related devices. Method aspects will be in part
apparent and in part explicitly discussed in the description
below.
FIGS. 1 and 2 are perspective views of an exemplary embodiment of a
pyrotechnic circuit protection module, referred to herein as a
pyrotechnic disconnect module 100 according to the present
invention. The pyrotechnic disconnect module 100 generally includes
a nonconductive housing 102 and first and second terminals 104, 106
extending from and exposed on opposing sides of the housing 102.
The terminals 104, 106 provide a connection structure to external
circuitry, and in the example shown the terminals 104, 106 are flat
terminals including a mounting aperture that may provide, for
example, connections to terminal studs of a power distribution
block, or bolt-on connection to a another conductor. Other types of
terminals known in the art may likewise be used instead in other
alternative embodiments. Also, in other embodiments, the terminals
104, 106 instead of being the same type as in the example shown may
be different types relative to one another. It is also understood
that in another embodiment the terminals 104, 106 may project from
or be exposed by other locations in the housing 102, including but
not limited to an embodiment wherein the terminals 104, 106 extend
from the same side of the housing 102.
In the example shown, the housing 102 has a generally rectangular
shaped outer profile defined by a top face or surface 108, a bottom
face or surface 110 opposing the top surface 108, lateral side
faces or surfaces 112, 114, and longitudinal side faces or surfaces
116, 118. A recess 120 is formed adjacent the terminal 106 on the
lateral surface 112 and a portion of the housing 102 overhangs the
terminal 106 on the lateral side 112, while a clearance or cutout
122 is formed in the housing 102 beneath the terminal 106 on the
lateral side 112. The terminal 104, however, projects away from the
housing at the opposing side without an overhang or cutout formed
in the housing 102 at the lateral side 114. The housing 102
accordingly has an asymmetrical shape in the example shown. Other
geometric shapes and geometries, including symmetrical shapes, are
possible in other embodiments.
As also shown in FIGS. 1 and 2, the longitudinal sides 116, 118 of
the pyrotechnic disconnect module 100 each include respective
electrical connectors 124, 126 exposed thereon. In the example
shown, the connector 124 is a female connector and the connector
126 is a male connector. The connectors 124, 126 in the illustrated
example, generally oppose one another and are in-line with one
another in the same location vis-a-vis the opposing sides 116, 118
of the pyrotechnic disconnect module 100. That is, the connectors
124, 126 are located at the same elevation and spacing from the
respective sides 108, 114 of the housing 102. As such, aligned
pyrotechnic disconnect modules 100 can be electrically connected to
one another via the male connector 126 on a first pyrotechnic
disconnect module 100 and a female connector 124 on a second
pyrotechnic disconnect module 100 using a plug and socket-type
engagement.
When the respective electrical connectors 124, 126 of two adjacent
pyrotechnic disconnect modules 100 are joined and mated as in the
example systems described below, electrical interconnection of the
pyrotechnic disconnect modules 100 is established for control and
coordination purposes described below in a pyrotechnic circuit
protection system. While exemplary male and female connectors 126,
124 are shown at exemplary locations in the pyrotechnic disconnect
100 and also while a two prong male connector 126 and a two
aperture female connector 124 are provided, other types of male and
female connectors 126 may be utilized in other embodiments, whether
in the same or different locations on the housing 102, in other
embodiments.
The electrical connector 124 and 126 in each pyrotechnic module 100
is electrically connected via the first male prong and the first
mating aperture to a pyrotechnic disconnect element 128 (FIG. 5)
inside the module housing 102. The pyrotechnic disconnect element
128 may be activated by control circuitry in the manner described
below to release stored energy inside the module 100 in a known
manner to open or disconnect a conductive circuit path between the
terminals 104, 106 in a known manner. Generally, any known type of
pyrotechnic element 128 and associated type of energy storage
element (e.g., chemical, electrical, mechanical) known in the art
may be utilized inside the pyrotechnic disconnect module 100.
A power supply and electronic control circuit 130 (FIG. 5) may also
be included in the pyrotechnic disconnect module 100. When a
trigger command is received by the control circuit 130 via one of
the connectors 124, 126 the pyrotechnic element 128 is activated by
the power supply to cause the energy to be released that, in turn,
opens or disconnects the terminals 104, 106 of the module 100.
The control circuitry of the module 100 may include a
processor-based microcontroller including a processor and a memory
storage wherein executable instructions, commands, and control
algorithms, as well as other data and information required to
satisfactorily operate as described are stored. The memory of the
processor-based device may be, for example, a random access memory
(RAM), and other forms of memory used in conjunction with RAM
memory, including but not limited to flash memory (FLASH),
programmable read only memory (PROM), and electronically erasable
programmable read only memory (EEPROM).
As used herein, the term "processor-based" microcontroller shall
refer not only to controller devices including a processor or
microprocessor as shown, but also to other equivalent elements such
as microcomputers, programmable logic controllers, reduced
instruction set (RISC) circuits, application specific integrated
(ASIC) circuits and other programmable circuits, logic circuits,
equivalents thereof, and any other circuit or processor capable of
executing the functions described herein. The processor-based
devices listed above are exemplary only, and are thus not intended
to limit in any way the definition and/or meaning of the term
"processor-based".
The power supply for the control circuit 130 in contemplated
embodiments may be line voltage (either separately supplied or
derived from the circuitry protected with the pyrotechnic circuit
protection module 100), an isolated power supply, or may employ one
or more power harvesting supplies. Potential power sources and
supplies in contemplated embodiments also include the use of power
resistors to limit AC line voltage, rectified AC line voltages,
voltage regulators, voltage drops across Zener diodes, voltage drop
across power capacitors or supercapacitors, and/or a battery power
supply or battery bank. Renewable energy sources such as solar
power and wind power may also be utilized.
A pass through electrical connection is also established in the
housing 102 via the connectors 124 and 126 of each pyrotechnic
disconnect module 100 for the purposes described below. A number of
pyrotechnic disconnect modules 100 may therefore be electrically
connected to one another in a daisy chain arrangement vis the
connectors 124, 126 provided, and a continuity check can be made
through the connected string of pyrotechnic disconnect modules 100
to verify and account for all connected pyrotechnic disconnect
modules 100 via the second prong and the second aperture in the
connectors 126 and 124. Activation signals may be sent via the
connectors 124, 126 from a control module described below to
activate the pyrotechnic disconnect element 128 in each module 100
individually in an independent manner, or to activate the
respective pyrotechnic elements 128 in the connected modules 100
simultaneously as desired.
FIG. 3 is a perspective view of an exemplary embodiment of a
modular pyrotechnic control module 140 for use with the pyrotechnic
circuit protection device module(s) 100 (FIGS. 1 and 2).
The pyrotechnic control module 140 generally includes a
nonconductive housing 142 and first and second terminals 144, 146
extending from and exposed on opposing sides of the housing 142.
The terminals 144, 146 provide a connection structure to external
circuitry, and in the example shown the terminals 144, 146 are flat
terminals including a mounting aperture that may provide, for
example, connections to terminal studs of a power distribution
block, or bolt-on connection to a another conductor. The terminals
144, 146 are similar to the terminals 104, 106 of the pyrotechnic
disconnect module 100 described above. Other types of terminals
known in the art may likewise be used instead in other alternative
embodiments, and the terminal structure in the pyrotechnic control
module 140 need not be the same as the terminal structure in the
pyrotechnic disconnect module(s) 100 in all embodiments. Also, in
other embodiments, the terminals 144, 146 instead of being the same
type as in the example shown may be different types relative to
another. It is also understood that in another embodiment the
terminals 144, 146 may project from or be exposed by other
locations in the housing 142 of the module 140, including but not
limited to an embodiment wherein the terminals 144, 146 extend from
the same side of the housing 142.
In the example shown, the housing 142 of the pyrotechnic control
module 140 has a generally rectangular shaped outer profile defined
by a top face or surface 148, a bottom face or surface 150 opposing
the top surface 148, lateral side faces or surfaces 152, 154, and
longitudinal side faces or surfaces 156, 158. Unlike the housing
102 of the pyrotechnic disconnect module 100, the housing 142 of
the pyrotechnic control module 140 has a symmetrical shape in the
example shown. The sides 156, 158 of the control module housing 142
are generally square sides having edges of approximately equal
length, whereas the sides 116, 118 of the pyrotechnic disconnect
module housing 102 include side edges of substantially different
length. Other geometric shapes and geometries, including
asymmetrical shapes of the control module 140, are possible in
other embodiments. It is noted that the shape and profile of the
pyrotechnic control module 140 is visibly different from the
pyrotechnic circuit protection module 100 (FIGS. 1 and 2) in both
shape and proportion so that the two pyrotechnic modules 100, 140
can be readily identified and distinguished in use. Beneficially,
the two modules 100, 140 cannot easily be mistaken for one another
in assembling the modules into a system such as those described
below.
The pyrotechnic control module 140 includes an electrical connector
in the form of a two aperture female connector 124 on one of the
lateral sides 156, 158 of the housing 142. The connector 124 is
located at the same elevation as the corresponding connector 124 in
the pyrotechnic disconnect module 100. Using the connector 124, the
control module 140 may be aligned side-by-side with and be
connected to a pyrotechnic circuit protection module 100 via the
connector 126 of the module 100 to configure a pyrotechnic circuit
protection system as further described below. The control module
140, however, may alternatively include the male connector 126
instead of the female connector 124 in the embodiment shown.
Further, in still another embodiment the control module 140 could
include male and female connectors on opposing sides thereof,
either of which could be connected to one of the pyrotechnic
circuit protection modules 100.
The control module 140 may be a processor-based device
communicating with a remote device 160 via a wire or cable 170. The
remote device 160 may input signals to the control module 140 or
may be responsive to output signals from the control module 140.
The control module 140 may include a processor-based
microcontroller including a processor and a memory storage wherein
executable instructions, commands, and control algorithms, as well
as other data and information required to satisfactorily operate as
described. The memory of the processor-based device may be, for
example, a random access memory (RAM), and other forms of memory
used in conjunction with RAM memory, including but not limited to
flash memory (FLASH), programmable read only memory (PROM), and
electronically erasable programmable read only memory (EEPROM).
As used herein, the term "processor-based" microcontroller shall
refer not only to controller devices including a processor or
microprocessor as shown, but also to other equivalent elements such
as microcomputers, programmable logic controllers, reduced
instruction set (RISC) circuits, application specific integrated
(ASIC) circuits and other programmable circuits, logic circuits,
equivalents thereof, and any other circuit or processor capable of
executing the functions described herein. The processor-based
devices listed above are exemplary only, and are thus not intended
to limit in any way the definition and/or meaning of the term
"processor-based".
The remote device 160 in one embodiment may be a monitoring system
that in a known manner detects electrical fault conditions (e.g.,
electrical overcurrent conditions) in the circuitry connected to
one or more of the pyrotechnic circuit protection modules 100. The
monitoring system in such a scenario may be a separately provided
processor-based device in communication with voltage sensors,
current sensors or other sensors for detecting electrical fault
detections. Other possible sensors for detection of fault
conditions may include thermal sensors, vibration sensors, pressure
sensors, acoustic sensors, fluid sensors, and light sensors. Signal
inputs from one or more sensors such as those above may be received
and compared by the monitoring system to predetermined trigger
command set points or thresholds to determine whether or not to
activate a pyrotechnic circuit protection module 100. If inputs
from the sensors are below the applicable thresholds no fault
conditions are determined to exist and the signal inputs will
continue to be monitored. On the other hand, as inputs from the
sensors reach or exceed the applicable thresholds, electrical fault
conditions are determined to exist and trigger commands may be sent
from the monitoring system 160 to the control module 140 via the
cable 170. The control module 140 may then communicate the trigger
signal to the affected pyrotechnic circuit protection module(s)
100.
In another contemplated embodiment, the comparison(s) of sensed
values to trigger set point values may be made by the control
module 140 itself based on supporting data from the remote device
160, or still alternatively based upon its own sensing or
monitoring capability. For instance, the pyrotechnic control module
140 may monitor electrical conditions sensed across another element
in the circuit (e.g., one or more electrical fuses such as the fuse
208 (FIGS. 4 and 5)), and based on the monitored conditions make
the comparison to predetermined trigger set points and when
necessary issue trigger commands. Various different techniques of
monitoring circuit conditions across a fuse using voltage and
current sensing circuitry to detect electrical fault conditions are
known and may be utilized by the pyrotechnic control module
140.
Once electrical fault conditions are determined as described above,
whether by the control module 140 itself or by the remote device
160, the control and actuation module 140 sends an activation
signal to one or more of the pyrotechnic circuit protection modules
100 so that disconnection through the pyrotechnic circuit
protection module(s) 100 can be effected to protect connected
circuitry on the load side. Notification signals or messages can be
sent from the pyrotechnic control module 140 to the remote device
160 so that further appropriate actions can be taken in response to
the pyrotechnic disconnections made, including but not limited to
generation of notices or alerts to responsible personnel so that
the circuitry may be restored by replacing the activated and opened
pyrotechnic disconnection modules.
To summarize, and in view of the above, in contemplated
embodiments, electrical fault detection and determination may be
undertaken externally by the remote device 160, may be undertaken
by another device or system and communicated to the control module
140 by the remote device 160, may be detected and determined by the
control module 140 itself, or in some cases, trigger command
signals may also be generated manually or programmed by another
system or equipment associated with the electrical power system. As
such, the control module 140 may be responsive to actions taken by
a person or other equipment in a proactive manner, regardless of
whether or not fault conditions may actually be present at the
pyrotechnic disconnect module 100.
To facilitate communication between the control module 140 and an
external device 160, the wire or cable 170 in contemplated
embodiments may include a ground conductor to support control
electronics in the remote device 160 and/or in the control module
140. The cable 170 may also include an input signal conductor for
communication of command signals and data to the control module 140
as well as test and diagnostic signals on the same signal wire or
an additional signal wire in the cable 170. When trigger command
signals are received by the control module 140 over the cable 170,
the control module 140 can output trigger command signals to one or
more of the connected pyrotechnic circuit protection modules 100
via the connector 124 of the control module 140. As such, a single
control module 140 may coordinate and control a plurality of
pyrotechnic circuit protection modules 100, as well as communicate
with the remote device 160.
The control module 140 in contemplated embodiments may be powered
by line voltage (either separately supplied or derived from the
circuitry protected with the pyrotechnic circuit protection modules
100), an isolated power supply, or by utilizing known power
harvesting technologies. Potential power sources and supplies in
contemplated embodiments also include the use of power resistors to
limit AC line voltage, rectified AC line voltages, voltage
regulators, voltage drops across Zener diodes, voltage drop across
power capacitors or supercapacitors, and/or a battery power supply
or battery bank. Renewable energy sources such as solar power and
wind power may also be utilized.
FIG. 4 is a perspective view of a first exemplary embodiment of
pyrotechnic circuit protection system 200 according to the present
invention, and FIG. 5 is a block diagram of the system 200. The
system 200 as shown includes one pyrotechnic disconnect module 100
and one pyrotechnic control module 140. The modules 100 and 140 are
positioned side-by-side and are mechanically and electrically
interconnected by the respective female connector 124 (FIG. 3) of
the module 140 and the male connector 126 (FIG. 2) of the module
100 with plug-in connection. Bus bars 204, 206 are connected to the
terminals 106, 104 of the module 100 and to the terminals 144, 146
of the module via bolt connections, and the bus bars 204, 206 may
in turn be connected to external circuitry in a similar manner. As
seen in FIG. 5, the bus bar 204 may be connected to line-side or
power supply circuitry 180, and the bus bar 206 may be connected to
load-side circuitry 190. In other embodiments terminals other than
bus bars may be utilized to make such connections, including
terminal screw connectors, soldered connections, brazed connections
or other connection techniques known in the art using known
fasteners and the like.
The system 200 also includes a high voltage, low amperage fuse 208
for arc quenching purposes when the pyrotechnic circuit protection
module 100 is activated to disconnect or open an electrical
connection between the terminals 104, 106. The fuse 208 is
connected to the bus bars 204, 206 via terminal elements similar to
those shown for the modules 100, 140. The fuse 208 establishes a
current path in electrical parallel to the pyrotechnic circuit
protection module 100. When the circuit path between the terminals
104, 106 of the pyrotechnic circuit protection module 100 is
opened, current is then diverted through the fuse 208. The fuse 208
includes an arc extinguishing media or other arc quenching feature
to dissipate electrical arcing potential inside the fuse 208 as the
fusible element therein opens. By this arrangement, the pyrotechnic
circuit protection module 100 need not itself include arc
mitigation features.
In normal operation, when no electrical fault condition exists, the
pyrotechnic circuit protection module 100 provides a low resistance
circuit path between its terminals 104, 106. The fuse 208, however,
exhibits a relatively higher electrical resistance, and as such
very little current will flow through the fuse in normal
conditions. Instead, almost all of the current in normal conditions
will flow through the pyrotechnic circuit protection module 100.
Depending on the circuitry being protected and its electrical
arcing potential, the fuse 208 may in some instances be considered
optional and may be omitted in the system 200.
A housing base 210 and housing cover 212 may be provided as shown
to protect the components of the system 200 when interconnected as
shown. The base 210 defines a receptacle sized and dimensioned to
receive the modules 100, 140 and the arc mitigation fuse 208. The
cover 212 in the example shown includes an aperture through which
the cable 170 may pass. The cover 212 may in some embodiments be
transparent. In other embodiments, the cover 212 may be color coded
to convey to a person the type of disconnect modules 100 included
without having to open the cover 212 for inspection. While an
exemplary housing is shown and described, other variations of
housings are possible and may be utilized as desired. In certain
embodiments, the housing may be considered optional and may be
omitted in the system 200.
FIG. 6 is a perspective view of a second exemplary embodiment of a
pyrotechnic circuit protection system 250 according to the present.
The system 250 includes three pyrotechnic disconnect modules 100, a
control module 140, and the optional arc mitigation fuse 208. The
system 250 includes bus bar terminals 254, 256 that are larger than
the bus bars 204, 206 of the system 200, but are otherwise
similar.
The three pyrotechnic disconnect modules 100 are electrically
connected one another and to the module 140 via the respective
connectors 124, 126 described above. The three pyrotechnic
disconnect modules 100 are electrically connected to one another in
parallel between the bus bar terminals 254, 256 so that
collectively they may accommodate a greater amount of current
flowing between the bus bars 254, 256 than any individual one of
the pyrotechnic disconnect modules 100 could handle. Compared to
the system 200 (FIG. 4), the system 250 can accordingly operate
with larger current input to achieve a higher amperage rating for
the system 250.
As described above, either by itself or in response to an incoming
signal from the cable 170, the pyrotechnic control module 140 may
activate the pyrotechnic disconnect modules 100 independently or as
a group. While three pyrotechnic disconnect modules 100 are shown,
greater or fewer numbers of pyrotechnic disconnect modules 100 may
be provided in further and/or alternative embodiments. The system
250 is also shown to include a housing base 260 and cover 262 that
is larger than the housing base 210, 212 in the system 200, but
otherwise is similar.
FIG. 7 is a perspective view of a third exemplary embodiment of
pyrotechnic circuit protection system 300 according to the present
invention.
The system 300 includes four pyrotechnic disconnect modules 100,
and a control module 140 in communication with the pyrotechnic
disconnect modules 100 via the cable 170. As such, the control
module 140 may be located at a distance from the pyrotechnic
disconnect modules 100. The cable 170 may be provided with
corresponding connectors 124, 126 to plug the cable 170 into the
pyrotechnic disconnect modules 100 on one end and to the
pyrotechnic control module 140 on the other. The control module 140
may communicate with the remote device 160 via another cable 170.
In some embodiments the remote device 160 could likewise be
directly connected to the pyrotechnic disconnect modules 100
without utilizing the control module 140.
The system 300 also includes the optional arc mitigation fuse 208
for the same reasons previously explained. The system 300 includes
bus bars terminals 304, 306 that are larger than the bus bars 254,
256 of the system 250, but are otherwise similar.
The four pyrotechnic disconnect modules 100 are electrically
connected to one another via the respective connectors 124, 126
described above. The four pyrotechnic disconnect modules 100 are
electrically connected to one another in parallel between the bus
bar terminals 304, 306 so that collectively they may accommodate a
greater amount of current flowing between the bus bars 304, 306
than any individual one of the pyrotechnic disconnect modules 100
could handle. Compared to the system 250 (FIG. 6), the system 300
can accordingly operate with larger current input to achieve a
higher amperage rating for the system 300.
As described above, the pyrotechnic control module 140 and/or the
remote device 160 may activate the disconnect elements 128 in the
pyrotechnic disconnect modules 100 independently or as a group.
While four pyrotechnic disconnect modules 100 are shown in FIG. 7,
greater or fewer numbers of pyrotechnic disconnect modules 100 may
be provided in further and/or alternative embodiments. The system
300 is also shown to include a housing base 360 and cover 362 that
is larger than the housing base 210, 212 in the system 200, but
otherwise is similar.
FIG. 8 is a perspective view of a fourth exemplary embodiment of
pyrotechnic circuit protection system 400 according to the present
invention including six pyrotechnic disconnect modules 100, and
another exemplary embodiment of a pyrotechnic control module 402 in
communication with the pyrotechnic disconnect modules 100 via the
cable 170.
The six pyrotechnic disconnect modules 100 are shown to be
connected in three pairs of series connected modules 100 between
bus bar terminals 404, 406. This arrangement allows the system 400
to operate at higher voltages and/or to provide system redundancy
and improved reliability.
The connector 124, 126 of each module 100 in the system 400 is
mated with the connector 124, 126 of the adjacent module in each
pair of series connected modules 100. As such, the three modules
100 on the left hand side in FIG. 8 are connected to one another
via the module connectors 124, 126, and so are the three modules
100 on the right hand side. Each group of three connected modules
100 is further connected to the control module 402, which as shown
in FIG. 9, includes two connectors 124 instead of one connector 124
as in the module 140 described above. The module 402 is
proportionately larger than the module 140 to span the two groups
of modules 100 shown in FIG. 400. The module 402 is functionally
similar to module 140 in use to output trigger command signals to
activate the disconnect elements 128 in the pyrotechnic disconnect
modules 100 when desired. The two connectors 124 in the control
module 402 provide dual outputs, one to each group of three
connected modules 100 in the system 400.
Like the module 140 described above, the control module 402 either
by itself or in response to an incoming signal from the cable 170,
may activate the pyrotechnic disconnect modules 100 independently
or as a group. While three pyrotechnic disconnect modules 100 are
shown in each group, greater or fewer numbers of pyrotechnic
disconnect modules 100 may be provided in further and/or
alternative embodiments. A housing base and cover similar to those
described above in the previous systems may optionally be utilized
in the system 400 as desired.
The system 400 also includes an optional arc mitigation fuse 410
that is larger and operable under higher voltage than the fuse 208
in the systems 200, 250, 300 described above, but otherwise serves
the same purpose. The system 400 includes bus bar terminals 404,
406 that are larger than the bus bars 204, 206 of the system 200,
but are otherwise similar.
FIG. 10 is a perspective view of a fifth exemplary embodiment of
pyrotechnic circuit protection system 500 according to the present
invention.
The system 500 includes series-connected disconnect modules 100 in
connected groups of three as in the system 400. Instead of using
the dual output control module 402 of the system 400, the system
500 uses the control module 140 connected to one of the groups of
modules via the connectors 124, 126, and a jumper element 502
connecting the two groups of connected modules 100 in series with
one another for control purposes. The jumper element 502 in
contemplated embodiments includes a set of connectors 124 or 126 to
facilitate the series connection of the modules 100 as shown.
The control module 140, either by itself or in response to an
incoming signal from the cable 170, may activate the pyrotechnic
disconnect modules 100 independently or as a group. While three
pyrotechnic disconnect modules 100 are shown in each group, greater
or fewer numbers of pyrotechnic disconnect modules 100 may be
provided in further and/or alternative embodiments.
The system 500 also includes the optional arc mitigation fuse 410.
The system 500 includes bus bar terminals 504, 506 that are larger
than the bus bars 204, 206 of the system 200, but are otherwise
similar. A housing base and cover similar to those described above
in the previous systems may optionally be utilized in the system
500 as desired.
FIG. 11 is a perspective view of a sixth exemplary embodiment of a
pyrotechnic circuit protection system 600 according to the present
invention.
The system 600 includes the control module 140 and three
pyrotechnic disconnect modules 100 interconnected to one another by
the connectors 124, 126. Full voltage and amperage limiters 608 are
connected in series with each disconnect module 100 between bus bar
terminals 604, 606. The limiters 608 may be current limiting fuses
that provide mechanical backup for the control module 140 in an
electrical fault condition and/or aid in arc mitigation with the
optional arc limiting fuse 410. Other types of current limiters are
known, however, and may be utilized for similar purposes. A contact
bridge 610 is also shown to connect the control module 140 to the
bus bar 604. A housing base and cover similar to those described
above in the previous systems may optionally be utilized in the
system 600 as desired.
It should now be evident that still further variations of
pyrotechnic circuit protection systems may easily be assembled by
adding or subtracting disconnect modules and varying the
interconnections between them and the other elements described.
Having now described the modules 100, 140 and 402, those in the art
may construct control circuitry to implement the controls without
further explanation. Any programming of a controller may be
accomplished using appropriate algorithms and the like to provide
the desired effects, which is believed to be within the purview of
those in the art.
Relative to existing pyrotechnic circuit protection devices and
systems, the pyrotechnic circuit disconnect modules, pyrotechnic
control modules and configurable systems including the same
facilitate a desirability and expanded use of pyrotechnic
disconnect features in at least the following aspects.
The configurable pyrotechnic circuit protection system of the
invention readily facilitates the use of pyrotechnic disconnection
features in Arcflash Reduction Maintenance Systems (ARMS) now in
use in different types of fuse platforms, but not readily
compatible with conventional pyrotechnic disconnect devices.
Various different pyrotechnic circuit protection systems of the
invention, including but not limited to the examples above, are
easily configurable for many applications with a small number of
standard modular devices and modular components. A large variety of
different systems can be assembled that meet various different
needs for particular applications without customization and related
expenses and difficulty. The configurable pyrotechnic circuit
protection systems of the invention with modular components
reduces, if not eliminates, a need to develop a new pyrotechnic
disconnect feature for different applications.
The modular pyrotechnic components of the invention provide
advantageous economies of scale that reduce costs of providing
pyrotechnic disconnect features, as well as simplifies inventories
of parts needed to provide a full spectrum of systems for a vast
variety of different applications presenting different needs.
The use of pyrotechnic disconnect features in the proposed systems
of the invention advantageously facilitates circuit protection
systems operable with lower resistance for fusible applications.
Consequently, the systems of the invention are operable with lower
Watts loss, cooler operation, and improved cycle/fatigue life for
fusible applications
The proposed pyrotechnic circuit protection systems of the
invention facilitate management and coordination of multi-phases of
multi-phase power systems, and eliminate undesirable single phase
disconnection events in the multi-phase power system.
The built-in control functionality of the pyrotechnic actuation of
the invention provides easy and convenient interconnection
capability that reduces installation costs and complexity of
otherwise individually installed and stand-alone pyrotechnic
circuit protection devices. The control functionality of the
pyrotechnic actuation provides ease of connection and networking of
the proposed configurable pyrotechnic protection systems with other
systems (e.g., an arc sensing system as one example). Remote
operation of the control functionality of the pyrotechnic
protection system is likewise facilitated by interconnection of
multiple modular pyrotechnic protection devices to a single control
module.
The benefits and advantages of the inventive concepts are now
believed to have been amply illustrated in relation to the
exemplary embodiments disclosed.
A modular pyrotechnic circuit protection system has been disclosed
including at least one pyrotechnic disconnect module. The at least
one pyrotechnic disconnect module includes a nonconductive housing
including opposed side surfaces, a first electrical connector on
one of the opposed side surfaces, a second electrical connector on
the other of the opposed side surfaces, a pyrotechnic disconnect
element inside the nonconductive housing and electrically connected
to at least one of the first and second electrical connectors, and
first and second terminals coupled to the housing for connection to
external circuitry.
Optionally, the first electrical connector may be a male connector
and the second electrical connector may be a female connector. A
pass through electrical connection may be established in the
housing from the first electrical connector to the second
electrical connector. The pyrotechnic element may be configured to
release one of chemical energy, electrical energy or mechanical
energy to disconnect the first and second terminals. The
nonconductive housing may be asymmetrical. The at least one
pyrotechnic disconnect module may be in combination with a
pyrotechnic control module having at least one electrical connector
compatible with one of the first electrical connector and the
second electrical connector.
An embodiment of a modular pyrotechnic circuit protection system
has also been disclosed including a modular pyrotechnic control
module. The modular pyrotechnic control module includes a
nonconductive housing comprising opposed side surfaces, at least
one electrical connector on one of the opposed side surfaces, a
pyrotechnic control circuit inside the nonconductive housing and
electrically connected to the at least electrical connector, and
first and second terminals coupled to the housing for connection to
external circuitry.
Optionally, the at least one electrical connector may be one of a
male connector or a female connector. The system may further
include a cable for communicating with a remote device. In response
to a detected electrical fault condition, the pyrotechnic control
circuit outputs a trigger command signal to at least one
pyrotechnic disconnect module via the at least one electrical
connector. The nonconductive housing may be symmetrical. The
pyrotechnic control module of may be in combination with at least
one pyrotechnic disconnect module having an electrical connector
compatible with the at least one electrical connector. The at least
one electrical connector on one of the opposed side surfaces may
include a first connector and a second connector on the same one of
the opposing side surfaces.
A pyrotechnic circuit protection system has also been disclosed
including a first connection terminal, a second connection
terminal, and a plurality of pyrotechnic modules connected between
the first and second connection terminals, each of the plurality of
pyrotechnic modules including a nonconductive housing and
electrical connectors facilitating plug-in connection of the
pyrotechnic modules to one another.
Optionally, the plurality of pyrotechnic modules includes at least
one pyrotechnic disconnect module and a pyrotechnic control module.
The plurality of pyrotechnic modules may also include a plurality
of pyrotechnic disconnect modules each having a pyrotechnic
disconnect element. The plurality of pyrotechnic modules may be
connected in parallel between the first connection terminal and the
second connection terminal. The plurality of pyrotechnic modules
may include pyrotechnic modules connected in series between the
first connection terminal and the second connection terminal. The
pyrotechnic circuit protection system of may also include at least
one of an arc mitigation element connected in parallel to the
plurality of pyrotechnic modules or a limiter element connected in
series at least some of the plurality of pyrotechnic modules. At
least one of the first connection terminal and the second
connection terminal may be a bus bar.
This written description uses examples to disclose the invention,
including the best mode, and also to enable any person skilled in
the art to practice the invention, including making and using any
devices or systems and performing any incorporated methods. The
patentable scope of the invention is defined by the claims, and may
include other examples that occur to those skilled in the art. Such
other examples are intended to be within the scope of the claims if
they have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
* * * * *